After
setting pretty stringent lubricant target cleanliness levels for our
equipment, we experienced problems with repeating and maintaining
the levels.
Our environment is extremely dusty and dirty. After numerous
attempts to eliminate variables (procedure, type of bottles used, and
filtering), we came up with a solution: sealing the vacuum pump and both
the line flush and final sample bottles in a 2 mil-thick Ziploc bag leaving
only
the sample tubing with the sample port quick-connect exposed. It is a
little bit tricky removing the lid and bottle from the pump, but after
a few
tries it becomes easier. (David Peraza,
Maintenance Lubrication Technician,
Cargill Salt)

Share your interesting case studies, personal expertise and new ideas
as a speaker at the 2007 Lubrication Excellence, Reliability World and
Lean Manufacturing Conferences, May 15-17 in Louisville, Kentucky. Send
abstracts and program ideas to awegener@noria.com.

Book
Bits: Observation of Lubricant Condition

From the "Handbook of Lubrication and Tribology"

An experienced observer of lubricant condition will give
considerable attention to the color of a lubricant sample - it is helpful
to compare with an unused sample. Oxidative and thermal breakdown of
a lubricant is often beyond exhausting its antioxidant reserve, gives
a darker, more brown, color. The deepening in color is also associated
with a characteristic "burnt" odor, which is recognizable when experienced.
The viscosity of the sample will also increase.

"Is there any way to tell if
an improper lubricant is being used without performing an oil analysis,
or without a part or system failure? We currently have an oil analysis
program in place, but I still find that wrong oils and fluids are being
used from time
to time, in between the oil analysis."

The most effective way to determine if wrong oil has been
used is by oil analysis, by looking at a change either in viscosity
and/or additive concentration. Unless there is a significant
difference in oil type (viscosity, base oil type, additives, etc.) or
any dye that may be used in the oil or grease, it is unlikely that a
sensory inspection is sufficient.

However, your problem
has little do to with oil analysis, but is more of a procedural issue.
Bottom line, we need to make those who are empowered with adding/changing
oil understand why adding the wrong oil is bad.

The first stage is
understanding through education, whether it be formal training or simply
internal training
sessions. Secondly, we need to make the process of adding oil as
foolproof as possible. The best way to achieve this is to practice lube
tagging.
In this approach, new oils are tagged with a designated color and
shape. For example, ISO VG 220 gear oil is given a red circle, AW 46
hydraulic
fluid a green square, etc.

The next step is to similarly label dedicated
oil transfer equipment such as oil top-off containers, funnels,
filter carts, etc.

Finally, label the gearboxes etc., with the same red
circle, green square etc. The strategy is simple: red-circle oil
gets added
to red-circle components using red-circle hardware. This can be
applied to all components and hardware, including greases, grease guns,
etc.